Multi-function in-case filling and capping system

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patent application Ser. No. 09/134,599, filed May 14, 1998 now abandoned by Bennett et al. for their “MULTI-FUNCTION IN-CASE FILLING AND CAPPING SYSTEM”, which application was based on U.S. provisional application serial No. 60/055,776 filed on Aug. 15, 1997.

BACKGROUND OF THE INVENTION

1. Field of the invention

The present invention relates to automated high-volume in-case filling and capping of containers and, more particularly, to an improved process and configuration for single or multiple lane, multi-function in-case filling and capping.

2. Description of the Background

The filling and capping process generally entails supplying bottles, containers, or cases containing bottles/containers along a conveyor, automatically filling them at a filling station, and automatically capping them at capping stations. Various testing and control functions may be performed along the way, for instance, testing and control of fill volume, cap torque, conveyor velocity, etc. The apparatus which performs the process must be capable of accommodating a wide variety of containers since they can vary in size, shape, neck angle, etc.

Existing filling and capping systems incorporate both rotary and linear machines. See, e.g., U.S. Pat. No. 5,301,488. In linear intermittent-motion machines, the containers are typically halted at each station for processing and/or testing. Thus, the throughput of such machines is limited by the capabilities of each station, and bottlenecks at any station can limit the total throughput.

U.S. Pat. No. 3,270,487 to Tchimenoglov is another early in-case filling and capping apparatus. Tchimenoglov et al. '487 shows a carrier 16 that transports cases from station to station (column 2, lines 56 et seq.), and a jig 36 mounted on the carrier 16 that clamps and lifts the bottles out of their cases at each station (column 2, lines 62-64). At each station the caseload of containers is held in a fixed position for the respective operations (filling, capping, etc.). There is no continuous-motion throughout the circuit nor tandem processes performed on multiple containers during the continuous-motion.

U.S. Pat. No. 5,419,099 to Mueller et al. shows a computerized system for filling containers I with food products. The system is designed to index individual containers by the use of a servo motor-driven conveyor assembly. Again the filling process is single-file and intermittent in nature. As with Tchimenoglov et al. '487, there is no teaching or suggestion of continuous-motion throughout the circuit, and the system is not capable of it. Moreover, there is no teaching or suggestion of tandem processes performed on multiple containers during the continuous-motion.

As an alternative to the foregoing linear devices, rotary machines work in a continuous motion, thereby providing increased filling and capping throughput. There have been efforts to increase the efficiency of the individual stations for both linear and rotary machines. For example, U.S. Pat. No. 5,301,488 to Ruhl et al. discloses a turret system for servo motor-operated intermittent indexing, filling, plugging, and capping functions. As stated at column 4, lines 48-53, a high-speed indexing turret positions the containers. The containers stop at two successive positions, first while a high-speed filling pump fills two-thirds of the container, and then while a second slower pump tops it off. (column 4, lines 59-64). Once again, the filling and capping process is single-file and intermittent in nature. There is no teaching or suggestion of continuous-motion throughout the circuit, and the system is not capable of it. Indeed, the extreme logistics of routing and then recombining containers in a rotary system prevents tandem processes performed on multiple containers during continuous-motion.

Clearly, there remains the potential for higher efficiencies and increased productivity, and it would be greatly advantageous to provide an apparatus capable of continuous motion and tandem operation using servo-mechanics plus software coordination between the filling and capping stations.

SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to provide improved processes and configuration for industrial filling and capping applications with greatly improved production rates over those that have been previously available.

It is another object of the present invention to provide a process and configuration for multiple-lane in-case filling and capping.

It is still another object to improve the station-to-station transfer efficiency in each lane of a multi-function in-case filling and capping system.

It is yet another object of the present invention to provide an improved process and configurations for multi-function in-case filling and capping which incorporates a quality control mechanism whereby fill volumes in each container may be monitored and reported, and whereby cap application and removal torque may also be monitored and reported.

In accordance with the above objects, one embodiment of an improved process and apparatus for multi-lane, multi-function in-case filling and capping of containers is provided in which cases of empty containers are received from an upstream conveyor loading process. Each case's major and minor flaps are opened, and each case is directed to flap control rails for maintaining the flaps in an open position throughout the filling and capping process. Each open case is inspected to confirm that the containers are present and are properly oriented within each case, while any improperly loaded cases are rejected from the system. The properly loaded or configured cases are then diverted into the least backlogged of a series of processing lanes, where the individual containers are filled. Screw thread caps or other closures are then applied to the containers, and the cases of filled and capped containers converge back together in a single discharge lane.

In another embodiment, the transfer efficiency of containers is improved by filling and capping the containers continuously, thereby making container/case indexing concurrent with the filling and capping processes, and increasing overall throughput.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and modifications thereof when taken together with the accompanying drawings in which:

FIG. 1 is a top perspective view of a conventional corrugated cardboard case <b>17</b> of the type that typically incorporates two or four containers <b>19</b> to be filled and capped by the system of the present invention.

FIG. 2 is a top perspective view of a multi-lane multi-function in-case filling and capping apparatus according to one embodiment of the present invention.

FIG. 3 is a block diagram illustrating how the PLC 23 interfaces with the other components and an optional personal computer.

FIGS. 4, <b>5</b> and <b>6</b> are a side view, top view and rear view, respectively, of an alignment mechanism <b>70</b> that ensures that caps are correctly applied to containers.

FIGS. 7-14 are sequential drawings illustrating the cap application process of one of the two identical cappers in assembly <b>10</b>.

FIGS. 15 and 16 are a top perspective view and a side view, respectively, of a flap opening system <b>2</b> as used in the two-lane, multi-function in-case filling and capping apparatus described above.

FIGS. 17 through 19 collectively comprise a flow chart illustrating the sequence of operation of the embodiment of FIG. 2 as administered by the programmable logic controller (“PLC”) to all connected components.

FIG. 20 is a top perspective view of a three-lane, multi-function in-case filling and capping apparatus according to a second embodiment of the present invention.

FIG. 21 is a top perspective view of a single-lane, multi-function in-case filling and capping apparatus incorporating continuous tandem filling and capping stations to improve the station-to-station transfer efficiency according to another embodiment of the present invention.

FIGS. 22 through 27 collectively comprise a flow chart illustrating the sequence of operation of the embodiment of FIG. 21 as administered by the PLC to all connected components.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a top perspective view of a typical corrugated cardboard case <b>17</b> incorporating four containers <b>19</b> of the type to be filled and capped by the system of the present invention. Groupings of containers <b>19</b> are seated in the cardboard case <b>17</b> in rows and may be separated by dividers. A. bar code <b>18</b> appears on the case itself, and the bar code <b>18</b> contains information about the cardboard case <b>17</b> and containers <b>19</b> situated therein such as product size, number and cap type. Each filling and capping job generally begins with adjustment of the equipment to handle a number of identical cases and containers, and the bar codes are used to insure uniformity. The present system will be described herein with reference to the illustrated containers, which have large measuring caps. However, it should be understood that the system and apparatus may readily be adapted for other case sizes and bottle or container arrangements, and other bottle or container types such as vials, sample receptacles and the like

FIG. 2 is a top perspective view of a two-lane, multi-function in-case filling and capping apparatus according to one embodiment of the present invention. The device is designed for automated high-volume filling and capping of containers <b>19</b> in cardboard cases <b>17</b> such as described above.

The cases <b>17</b> containing the empty containers <b>19</b> are placed at the start of a system conveyor <b>15</b> from the loading dock. Each empty case enters the system from the left and is conveyed through the system (from left to right) via the system conveyor <b>15</b>. System conveyor is a conventional track and roller-type conveyor fabricated from mild steel, and it supports the cases/containers throughout the process. There are a number of track and roller-type conveyors that are commercially available from, for example, Materials Handling Systems, Inc. (MHS) of Elkridge, Md., or AMBEC, Inc. of Owings Mills, Md. Other available conveyors may be equally well-suited for use in the present system.

The cases <b>17</b> are conveyed past a conventional bar code reader <b>20</b> which scans the bar code <b>18</b> (on the case <b>17</b>). Given the bar-coded information it is possible to verify case orientation at the optical inspection station <b>3</b> (to be described), as well as the contents to be dispensed. Bar code reader <b>20</b> is connected to a programmable logic controller (“PLC”) 23 with attached display output <b>24</b>. The bar-coded information is used to verify that each case entering the filling and capping areas matches the setup parameters of the equipment, such as fill volume and cap torque. Further, in a fully automated in-case filling and capping system, the bar code reader <b>20</b> can be used to initiate servo-operated setup and changeover processes whereby the system operation may be adjusted as necessary to provide for different filling and capping applications. In a typical semi-automated system, the scanned bar code information is displayed to provide the system operator with a checklist of the required manual changeover steps on an operator interface screen. There are a number of suitable bar code readers that are commercially available from, for example, Omron Electronics of Schaumburg, Ill.

If the bar code reading is acceptable, the case <b>17</b> proceeds along conveyor <b>15</b> to a flap opener <b>2</b>. The flap opener <b>2</b> (described more fully below) automatically opens all four flaps of the case.

From the flap opener <b>2</b> as shown, the case proceeds to an optical inspection station <b>3</b>. Optical inspection station <b>3</b> includes a commercially available camera or vision system, positioned directly above conveyor <b>15</b>. A suitable vision system is commercially available from Omron Electronics of Schaumburg, Ill., and this may be connected directly to PLC 23. Optical inspection station <b>3</b> also incorporates mechanical means for centering cases <b>17</b> during inspection, and for ejecting any non-conforming cases. A typical case positioning mechanism comprises a pivoting gate or stop finger, and ejection can be accomplished via a simple pusher bar assembly <b>4</b> which moves the non-conforming cases onto a rejected case collection conveyor <b>5</b>. Case collection conveyor <b>5</b> is a section of conventional track and roller conveyor positioned perpendicularly to conveyor <b>15</b>. A variety of acceptable gates, stop fingers, and pusher bar assemblies are commercially available, and these are connected to the PLC 23 for actuation thereby. Each open case is positioned in optical inspection station <b>3</b> where the vision system above inspection station <b>3</b> determines whether any containers are missing from the case, whether any pouring spouts are missing from the containers, and whether any containers are not properly oriented within the case. It is noteworthy that containers may have offset necks, and therefore orientation can be very important. Cases that fail at optical inspection station <b>3</b> due to the existence of any of the aforementioned conditions are rejected. This is accomplished by urging the failed cases off the system conveyor <b>15</b> by automatic pusher bar assembly <b>4</b>. The rejected cases are accumulated on case collection roller conveyor <b>5</b>. If the problem is corrected, the case can later be readmitted to the system (in front of the bar code reader <b>20</b>).

Cases that successfully pass at the optical inspection station <b>3</b> travel toward one of the parallel processing lanes <b>1</b>A and <b>1</b>B via a case directing system <b>6</b>. The conveyors of lanes <b>1</b>A and <b>1</b>B are off-shoots of conveyor <b>15</b>, and are likewise preferably fabricated of stainless steel with nylon rollers on stainless shafts, such that the conveyors of processing lanes <b>1</b>A and <b>1</b>B may be washed down in the event of product spillage.

The case directing system <b>6</b> is also connected to programmable logic controller (PLC) 23 which controls the direction of each case to the one of lanes <b>1</b>A or <b>1</b>B that has the least backlog of cases for processing.

The PLC 23 likewise directs the overall in-case filling and capping process, including setup parameters, diagnoses of fault conditions, sensing the level of caps in each prefeeder bin, monitoring of all sensors along the processing line, as well as the filling and capping operations themselves. A suitable PLC 23 is commercially available as the Allen-Bradley Model PLC-5/40, and this is preferably connected to a PC-based human/machine interface (HMI) display <b>24</b> which provides a full visual operator interface (an Allen-Bradley PanelView <b>900</b> is a suitable commercial HMI display). To coordinate and synchronize the operation of all active components, all of the following components are connected to the PLC 23: bar code reader <b>20</b>, flap opener <b>2</b>, optical inspection station <b>3</b>, case directing system <b>6</b>, first case indexing assemblies <b>9</b>A and <b>9</b>B, dual lane filling apparatus <b>7</b>, second indexing assemblies <b>13</b>A and <b>13</b>B, in-process quality control system, and dual lane capping apparatus <b>10</b>. Thus, the PLC 23 controls the entire program flow. The Allen-Bradley PLC 23 used herein includes a serial communication port (RS-232) by which it can be interfaced directly to a conventional personal computer to provide further control flexibility.

FIG. 3 is a block diagram illustrating how the PLC 23 interfaces with the above-named components including a personal computer <b>50</b>. The personal computer <b>50</b> is shown with connections to preferred peripheral components such as a conventional CD-ROM drive <b>52</b>, and a remote access modem <b>54</b>. The CD-ROM <b>52</b> allows instant access to a software instruction manual (with graphics and video clips) and other software help resources, and the modem <b>54</b> facilitates online communications for remote debugging or remote control of the entire system.

The computer can also be loaded with existing statistical process control software (SPC) such as RSView32 from Rockwell Software, Inc. of West Allis, Wis. to provide a graphical user interface and statistical output for closer control of the process.

Referring back to FIG. 2, case directing system <b>6</b> preferably is a skewed-wheel diverter commercially available from Roach Manufacturing Corporation, although other directing systems may be used. Each case enters case directing system <b>6</b> and is allowed to either proceed along the main conveyor lane <b>1</b>A or is diverted onto the secondary conveyor lane <b>1</b>B. Each of lanes <b>1</b>A and <b>1</b>B will direct the case to their respective filling process stations where they are filled by a dual-lane filling apparatus <b>7</b>. If for any reason one of the filling or capping machines becomes inoperable, all of the cases are directed onto the conveyor lane <b>1</b>A or <b>1</b>B of the filling and capping system that remains functional.

Once the case enters either lane <b>1</b>A or <b>1</b>B (prior to arrival at dual-lane filling apparatus <b>7</b>), the case proceeds to a respective case indexing assembly <b>9</b>A or <b>9</b>B. The first (filling area) case indexing assemblies <b>9</b>A and <b>9</b>B are each a continuous cleated servo-driven belt spanning the length of the filling area, the cleats of which engage each case to move it along system conveyor <b>15</b>. First case indexing assemblies <b>9</b>A and <b>9</b>B are each driven by conventional servos that are available from, e.g., Kollmorgen, Inc. of Radford, Va. The case indexing assembly <b>9</b>A or <b>9</b>B transports the case (under PLC 23 control) into the proper filling position under the tandem nozzles <b>72</b>A and <b>72</b>B of the filling apparatus <b>7</b>, and then transfers the case into respective capping area indexing assemblies <b>13</b>A and <b>13</b>B after the filling operation has been accomplished. Containers <b>19</b> are located in proper alignment below the tandem nozzles <b>72</b>A and <b>72</b>B, while a bar pushes on the outside surface of the case to drive it against a fixed stop positioned on the side of the conveyor that is closest to the frame of the filling machine <b>7</b>. The tapered tips of the tandem nozzles are sufficient to locate, or align, the neck openings of the containers <b>19</b> in the case during the filling process, and this maintains the containers themselves in proper alignment directly below the respective filling nozzles <b>72</b>A and <b>72</b>B.

Following proper placement of the containers <b>19</b> under the filling nozzles <b>72</b>A and <b>72</b>B, the nozzles are lowered into the openings of the containers. Air-operated valves in the tips of the nozzles open and the correct volume of liquid is dispensed. Servo-driven rotary lobe volumetric filling pumps are used to dispense the liquid into the containers, and suitable pumps are commercially available from Waukesha Co. Fluid Handling of Delavan, Wis., under its rotary piston pump line. After the containers <b>19</b> are properly filled, the nozzles close. A vacuum suck-off system located in the tip of the nozzle is actuated to control any drips. The nozzles are then lifted out of the containers. Suitable filling nozzles <b>72</b>A and <b>72</b>B including vacuum suck-off systems are commercially available from the National Instrument Company, Inc. of Baltimore, Md., and these may be arranged in tandem groups of 2 or 4, one group per line <b>1</b>A and <b>1</b>B.

An in-process quality control system is preferably incorporated to automatically determine inappropriate fill volumes which may then be adjusted automatically or by a system operator, and also to provide a measurement of the gross weight of each full case at the conclusion of each fill cycle. For this purpose, a conventional check-weight scale is located in the filling area and, on demand (at user-defined timed intervals), rises up under an empty case. Such check-weight scales are commercially available from, e.g., Mettler-Toledo, Inc. of Hightstown, N.J. In this manner the case can be tare-weighed. A test routine can be run in which a single filling pump is actuated and the fill volume delivered into a single container. The total weight will be tested, and a second container will then be filled and the overall weight determined. Each container in the case is individually filled and weighed, then the individual container weights are determined. If any of the fill volumes are out of specification because of a temperature change, a viscosity change or a change in specific gravity, the pump is automatically re-calibrated by the PLC 23 system. A servo is used to register the correct number of counts corresponding to the correct fill volume. Pump errors are flagged and the operator is notified.

After the filling operation is complete, the filled case is transferred by the first indexing system <b>9</b>A and <b>9</b>B to second capping area indexing assemblies <b>13</b>A and <b>13</b>B, and onward to dual

As with filling area indexing assemblies <b>9</b>A and <b>9</b>B, the capping area indexing assemblies <b>13</b>A and <b>13</b>B are each a continuous cleated servo-driven belt spanning the length of the capping area, the cleats of which engage each case to move it along system conveyor <b>15</b>. The capping area indexing assemblies <b>13</b>A and <b>13</b>B are also driven by conventional servos.

Each of the two cappers in assembly <b>10</b> is preferably a multi-spindle capping machine that is supplied with caps by a cap feeding/orientation system. The presently preferred capper is a Capamatic™ two spindle/capping chuck model that is commercially available from the National Instrument Company, Inc. of Baltimore, Md. The cap feeding/orientation system includes a common prefeeder assembly <b>11</b>, chutes <b>16</b>A and <b>16</b>B, and rotary cap feeder bowls <b>12</b>A and <b>12</b>B. At each capper of assembly <b>10</b>, caps are fed out of the common prefeeder assembly <b>11</b>. Prefeeder assembly <b>11</b> stores the caps to be used, and a thirty-cubic foot capacity is suitable. Caps are transferred by prefeeder assembly <b>11</b> down one of two chutes <b>16</b>A or <b>16</b>B into rotary feed bowls <b>12</b>A and <b>12</b>B. Rotary feed bowls <b>12</b>A and <b>12</b>B orient the caps and feed them into chutes <b>100</b>A and <b>100</b>B. The entire cap feeding/orientation system (inclusive of prefeeder assembly <b>11</b>, chutes <b>16</b>A and <b>16</b>B, and rotary cap feeder bowls <b>12</b>A and <b>12</b>B) is commercially available from Farason Corp. of Coatesville, Pa.

Chutes <b>100</b>A and <b>100</b>B deliver the caps to respective splitter plates each comprising a shallow guide plate with forked grooves for dividing caps between two transfer stations. The two capping chucks at each of the two cappers in assembly <b>10</b> pick up the caps from the respective transfer stations in each of the two splitter plates.

It has been found that the weight of the filled containers <b>19</b> resting on the uneven, internal surface of the bottom of the case results in a slight misalignment between the necks of those containers <b>19</b> and the two capping chucks present in each of the two cappers in assembly <b>10</b>. The misalignment is sufficient, however, to cause the capping mechanism to fail to correctly apply the caps to an intolerably high percentage of containers. To remedy this problem, an alignment mechanism is attached beneath each of the two capping chucks present in each of the two cappers in assembly <b>10</b>.

FIGS. 4, <b>5</b> and <b>6</b> are a side view, rear view and top view, respectively, of an alignment mechanism <b>70</b> that ensures that caps are correctly applied to containers. The alignment mechanism <b>70</b> is attached to the rear housing of each capping spindle (shown in dotted lines) and extends a pair of locator jaws <b>71</b> beneath the spindle to grab the neck of each container <b>19</b> just long enough to allow the threads of the cap to start to engage the threads on the container <b>19</b>. Once the threads are fully engaged, the locator jaws <b>71</b> open to provide sufficient clearance to allow the cap to be completely applied to the container <b>19</b>. This operation locates the containers <b>19</b> correctly for the capping chucks and acts as a gripping mechanism to stabilize the containers <b>19</b> during capping. With collective reference to FIGS. 4, <b>5</b> and <b>6</b>, alignment mechanism <b>70</b> generally includes the pair of pneumatic-controlled locator jaws <b>71</b> suspended from the spindle by an articulating actuator assembly <b>72</b>. Actuator assembly <b>72</b> is mounted to the spindle housing by a plate <b>73</b>, and this secures a pneumatic cylinder <b>74</b> directly behind the spindle. The pneumatic cylinder <b>74</b> is a commercially-available part from, for example, Bimba, Inc. A downwardly extending piston <b>75</b> is mounted in the pneumatic cylinder <b>74</b>, and a jaw actuator assembly <b>76</b> secures the locator jaws <b>71</b> to the distal end of the piston <b>75</b> directly beneath the capping chuck (dotted lines). The jaw actuator assembly <b>76</b> comprises a clamping block <b>77</b> for screw attachment to the downwardly extending piston <b>75</b>, and a gripper <b>78</b> secured to the clamping block for extending the locator jaws <b>71</b> outward toward the capping chuck. The gripper <b>78</b> is a commercially-available part from, for example, Robohand, Inc. The locator jaws <b>71</b> are formed as shown to provide a uniform griping force around the necks of the containers <b>19</b>, and the exact contour of the jaws will vary accordingly. The pneumatic cylinder <b>74</b> includes separate pneumatic inputs <b>79</b><i>a </i>&amp; <b>79</b><i>b </i>to control extension and retraction of piston <b>75</b>, and thus the locator jaws <b>71</b> can attain any combination of “up” and “open” or “down” and “closed”.

The operation of the articulating actuator assembly <b>72</b> of FIGS. 4-6 will now be described with reference to FIGS. 7-14, which are sequential drawings illustrating the cap application process of one of the two identical cappers in assembly <b>10</b>. The caps <b>192</b> are put onto the containers <b>19</b> sequentially, two-by-two, row-by-row, container by container, by the capping chucks of each of the two Capamatic™ multi-spindle capping machines. Thus, the two cappers in assembly <b>10</b> work in tandem

As shown in FIG. 7, the capping cycle begins with the capping mechanism's spindle assembly <b>120</b> and the locator jaws <b>71</b> of an alignment mechanism <b>70</b> in the “up” and “open” position.

As seen in FIG. 8, under servo control the spindle assembly <b>120</b> descends to pick up the cap from the splitter plate <b>192</b>. After grasping the cap <b>195</b>, the spindle assembly rises slightly allowing the splitter plate <b>192</b> to retract, passing just below the bottom edge of cap <b>195</b>. Once the splitter plate <b>192</b> has retracted, the alignment mechanism <b>70</b> and spindle assembly <b>120</b> descend to the “down” position.

As shown in FIGS. 9 and 10, the entire capping mechanism moves horizontally to match the capping area indexing assemblies <b>13</b>A and <b>13</b>B movement of the case and its filled containers <b>19</b>. While the capping chuck is in motion directly above the moving case <b>17</b> and filled containers <b>19</b>, the alignment mechanism <b>70</b> descends to the “down” position.

As shown in FIGS. 11 and 12, once the alignment mechanism <b>70</b> reaches the “down” position, the locator jaws <b>71</b> move to the “closed” position around the neck of the container <b>19</b>. After the neck of the container <b>19</b> has been grasped by the locator jaws <b>71</b>, and the case and its containers <b>19</b> are positioned beneath the capping chucks by indexing assemblies <b>13</b>A and <b>13</b>B, the capping chucks descend to apply the caps <b>192</b> to the container <b>19</b> neck openings.

As shown in FIGS. 13 and 14, as the threads on the cap <b>192</b> begin to engage the threads on the neck of the container <b>19</b>, the locator jaws <b>71</b> return to the “open” position. This must occur in order to provide the spindle assembly and the cap with complete access to the neck of the container <b>19</b>. Once the cap application process is complete and the cap has achieved the required application torque, the capping mechanism, spindle assembly, and alignment assembly <b>70</b> return to the start position.

After the caps have been put on the first two containers, the cases <b>17</b> in lanes <b>1</b>A and <b>1</b>B are indexed to the forward position to cap the second set of two containers. Thus, the chucks move across the first row of containers, across the second row, on to the next case, and so on. After the capping operation is completed, the case is released to travel to the combining area.

As the caps are being put on the containers, inspections for missing and cocked caps are made. The capping chucks are driven by a servo torquing mechanism, and a certain number of revolutions are required to install the cap correctly. If too few revolutions are performed, the cap is cocked. If too many revolutions are performed, then there is no cap in the chuck. Thus, this inspection process does not require sensors or a vision system. It is a function of the positional feedback capability of the Capamatic™ multi-spindle capping machines of capper assembly <b>10</b> (the servo motors used therein employ closed loop technology) and the programming of its control system. If, during a typical capping cycle, the number of revolutions of the capping chuck does not correspond with that contained in the control program (known to be the appropriate number to achieve successful application of the cap), something is wrong and the feedback is analyzed.

Preferably, the in-process quality control system is also configured to verify the capping machine application torque. During a test cycle, a cap is allowed to relax for approximately five seconds before it is carefully removed by the servo-chuck and the removal torque determined and reported. The caps will then be replaced and the finished case sent to a combining area. Any readout that is out of specification will be reported by the PLC 23. The in-process quality control check occupies thirty to sixty seconds depending upon the number of containers in a case.

After the containers are filled, capped and inspected, they proceed to a combining area where a case converging system <b>14</b>, commercially available from Roach Manufacturing Corporation, recombines the cases from the separate lanes into a single lane. From there, the cases are typically sent onward to a case sealer (not shown). Case converging system <b>14</b> controls the convergence of the cases into a single conveyor lane after the filling and capping processes have been completed.

FIGS. 15 and 16 are a top perspective view and a side view, respectively, of a flap opening system <b>2</b>, commercially available from Bay Design, Inc. of Baltimore, Md., as used in the two-lane, multi-function in-case filling and capping apparatus described above. The flap opening system comprises two powered rollers side belt assemblies <b>64</b>A and <b>64</b>B, a major flap opener plow assembly <b>65</b>, a servo-driven pivoting arm assembly, and a hook mechanism <b>66</b>. The cases are received with the major flaps partially opened from the upstream conveyor loading process. Each case travels along the system conveyor <b>15</b> until it is pulled into the flap opening system <b>2</b> by powered side belts <b>64</b>A and <b>64</b>B. The partially opened major flaps of the case are fully opened by the plow assembly <b>65</b>. The leading, minor flap of the case is pulled open by the pivoting arm assembly while the hook mechanism lifts the trailing, minor flap. Once all of the case flaps have been opened, the case enters the flap control rails <b>69</b>. Flap control rails <b>69</b> extend through the filling and capping functions before ending at a point just downstream from the capping area, and prevent the case flaps from closing.

FIGS. 17 through 19 collectively comprise a flow chart illustrating the sequence of operation of the embodiment of FIG. 2 as administered by the PLC 23 to all connected components.

At step <b>120</b> the main power is turned on.

At step <b>122</b> the operator performs machine setup for the cases and containers to be filled and capped.

At step <b>124</b> the PLC resets all connected components.

At step <b>126</b>, the PLC performs a self-test on all connected modules and returns to step <b>122</b> if a component fails to pass.

If all components pass the self-test, the PLC asks the operator if he wishes to enter the automatic cycle at step <b>128</b>. If the user indicates no, then the PLC initiates manual mode at step <b>130</b>. In manual mode, the user is prompted to initiate each control sequence one-by-one.

If the user initiates the jog filler at step <b>132</b>, the filling exercise sequence is carried out at step <b>133</b> and program flow proceeds to the next operation.

If the user initiates the jog capper at step <b>134</b>, the capping exercise sequence is carried out at step <b>135</b> and program flow proceeds to the next operation.

If the user initiates the prime filler at step <b>136</b>, the prime filling exercise sequence is carried out at step <b>137</b> and program flow proceeds to the next operation.

If the user initiates the jog indexer at step <b>138</b>, the indexing is carried out at step <b>139</b> and program flow proceeds to the next operation.

Finally, if the user initiates the cleaning cycle at step <b>140</b>, the cleaning cycle is carried out at step <b>141</b> and program flow returns for another job to step <b>128</b>.

Alternatively, if at step <b>128</b> the user instead selects automatic cycle, program flow proceeds accordingly to step <b>142</b> where the user is prompted to enter all necessary job, case, container and cap parameters.

At step <b>144</b>, the bar code scanner process is initiated. The bar code reader <b>20</b> of FIG. 2 outputs the bar-coded information to the PLC to verify that each case entering the filling and capping areas matches the setup parameters of the equipment, such as fill volume and cap torque.

Next, the case is indexed at step <b>146</b> into the optical inspection station <b>3</b>, and the optical inspection process is initiated at step <b>148</b>. Here the vision system of optical inspection station <b>3</b> determines whether any containers are missing from the case, and whether any containers are not properly oriented. Cases that fail the optical inspection station <b>3</b> at step <b>150</b> are rejected and are urged off the system conveyor <b>15</b> by automatic pusher bar assembly <b>4</b>, and accumulated on case collection roller conveyor <b>5</b>.

If the case passes at the optical inspection station <b>3</b> at step <b>150</b>, the case is transferred down conveyor <b>15</b> for the next process (see step <b>152</b>). At step <b>152</b>, the case is transferred to the case directing system <b>6</b>.

The cases are properly indexed by the first indexing assemblies <b>9</b>A and <b>9</b>B at step <b>154</b>, and each indexed case enters case directing system <b>6</b> and is allowed to either proceed along the main conveyor lane IA or is diverted onto the secondary conveyor lane <b>1</b>B depending on backlog.

At step <b>156</b> error conditions are flagged and displayed to the operator at step <b>171</b>

The first case indexing assemblies <b>9</b>A and <b>9</b>B position the respective cases for filling at step <b>158</b>. The PLC then initiates the filling process at step <b>160</b>, and the filling assemblies <b>72</b>A and <b>72</b>B fill the containers.

Assuming that the containers are properly filled at step <b>162</b>, the PLC directs the cases to be transferred to the capper <b>10</b> at step <b>164</b>, and this is accomplished at step <b>166</b>.

At step <b>168</b>, the cases are indexed onto the respective capping servo conveyors. If the cases are properly positioned at step <b>162</b>, each capper indexing assembly <b>13</b>A and <b>13</b>B positions the first row of containers in its case for capping at step <b>168</b>. The PLC then initiates the capping process at step <b>170</b>, and the capper <b>10</b> caps its containers from bowls <b>12</b>A and <b>12</b>B at step <b>170</b>. Upon completion, the caps are checked for errors at step <b>172</b> and, if no errors are present at step <b>178</b>, another case is retrieved by each indexing assembly <b>13</b>A and <b>13</b>B for capping at step <b>176</b>. Each indexing assembly <b>13</b>A and <b>13</b>B positions the second row of containers in its case for capping at step <b>180</b>. The PLC 23 then initiates the capping process at step <b>182</b>, and the capping apparatus <b>10</b> caps its containers from bowls <b>12</b>A and <b>12</b>B at step <b>182</b>. Upon completion, the caps are checked for errors at step <b>184</b> and, if no errors are present at step <b>186</b>, the cases are indexed out of the capper <b>10</b>, they are counted, and they are indexed out to case converging system <b>14</b> which recombines the cases from the separate lanes into the single lane on the output conveyor. The capper indexing assemblies <b>13</b>A and <b>13</b>B then initiate processing of the next cases. Once the last case has been processed at step <b>188</b>, the job ends at step <b>190</b>.

The dual lane capping and filling process greatly improves efficiency and throughput.

FIG. 20 is a top perspective view of a three-lane, multi-function in-case filling and capping apparatus according to a second embodiment of the present invention. The three-lane, multi-function in-case filling and capping apparatus of FIG. 20 is intended to illustrate the ease by which the basic configuration of the present invention can be expanded to any number of parallel lines.

FIG. 21 is a top perspective view of a single-lane, multi-function in-case filling and capping apparatus incorporating continuous-motion filling and capping stations to improve the station-to-station transfer efficiency according to another embodiment of the present invention. As before, the device is designed for automated high-volume filling and capping of containers <b>19</b> in cardboard cases <b>17</b> such as described previously, and other like components will herein be described with reference to like numbers.

The cases <b>17</b> containing the empty containers <b>19</b> are placed at the start of a single-line system conveyor <b>115</b> from the loading dock. Each empty case enters the system from the left and is conveyed through the system (from left to right) via the system conveyor <b>115</b>. As before, system conveyor <b>115</b> is a conventional track and roller-type conveyor as commercially available from, for example, MHS or AMBEC, Inc.

Likewise, the cases <b>17</b> are conveyed past a conventional bar code reader <b>20</b> which scans the bar code <b>15</b> (as described above).

After passing the bar code reader <b>20</b>, the case <b>17</b> proceeds along conveyor <b>1</b><b>15</b> to a flap opener <b>2</b>. As before, the flap opener <b>2</b> automatically opens all four flaps of the case.

Once the flaps have been opened, the case <b>17</b> proceeds along conveyor <b>115</b> to an optical inspection station <b>3</b> (as described above). The case is inspected to make sure that the containers are present and properly oriented. Optical inspection station <b>3</b> again incorporates means for centering cases <b>17</b> during inspection, and for ejecting any non-conforming cases via a pusher bar assembly <b>4</b> which moves the non-conforming cases onto a rejected case collection conveyor <b>5</b>. Each open case is indexed into optical inspection station <b>3</b> where the vision system at inspection station <b>3</b> determines whether any containers are missing from the case, and whether any containers are not properly oriented within the case. Cases that fail at the optical inspection station <b>3</b> are rejected and are urged off the system conveyor <b>115</b> by automatic pusher bar assembly <b>4</b>, and are accumulated on case collection roller conveyor <b>5</b>.

The open cases are then fed into the filling and capping area, where they proceed to a case indexing assembly <b>9</b>. Case indexing assembly <b>9</b> comprises a continuous cleated servo-driven belt spanning the length of the filling and capping area, the cleats of which engage each case to move it along system conveyor <b>115</b>. The case indexing assembly <b>9</b> transports each case (under PLC 23 control) into the proper filling position under the nozzles <b>72</b> of the filling apparatus <b>7</b>. Though capable of positioning cases singly, case indexing assembly <b>9</b> preferably transports the cases into the proper filling position in tandem pairs. The open cases travel down conveyor <b>115</b> in a properly spaced configuration (spaced so as to avoid damage to the flaps).

Once the cases enter the filling area, the containers <b>19</b> can be located in proper alignment below the nozzles <b>72</b>, while a bar pushes on the outside surface of the case to drive it against a fixed stop positioned on the side of the conveyor that is closest to the frame of the filling machine <b>7</b>. Thus, the containers are maintained in proper alignment directly below their respective filling nozzles <b>72</b>.

The filling apparatus <b>107</b> of the present embodiment includes a grouping of eight standard nozzles <b>72</b>. However, in this embodiment, nozzles <b>72</b> are mounted on a servo-controlled walking-beam that extends the entire length of the filling area. This allows the servo-controlled walking-beam filling apparatus <b>107</b> to move nozzles <b>72</b>. Thus, the nozzles <b>72</b> may be horizontally positioned in accordance with a conventional servo as available from, e.g., Kollmorgen, Inc. Moreover, the servo-controlled walking-beam filling apparatus <b>107</b> is connected to the PLC 23. This way, the travel of the servo-controlled walking-beam filling apparatus <b>107</b> can be synchronized to the travel of cases as transported by indexing assembly <b>9</b>.

Following proper positioning of the lead case and containers under the filling nozzles <b>72</b> on conveyor <b>115</b> (with a tandem case immediately behind), the nozzles are lowered into the openings of the containers in both cases. However, both cases of containers continue to be carried by indexing assembly <b>9</b> along conveyor <b>115</b>. The nozzles <b>72</b> of the walking-beam filling apparatus <b>107</b> track each pair of cases of containers along conveyor <b>115</b> as the air-operated valves in the tips of the nozzles <b>72</b> open and the correct volume of liquid is dispensed.

As before, servo-driven rotary lobe volumetric filling pumps are used to dispense the liquid into the containers, and suitable pumps are commercially available from Waukesha Fluid Handling under its rotary piston pump line. After the containers <b>19</b> are properly filled, the nozzles <b>72</b> close and the vacuum suck-off system located in the tip of the nozzle controls any drips. The nozzles are then lifted out of the containers in both cases simultaneously.

As soon as the containers in the first pair of cases are filled, the servo-controlled walking-beam filling apparatus <b>107</b> repositions the nozzles <b>72</b> over the next pair of cases and the containers therein.

As before, an in-process quality control system is preferably incorporated to automatically determine inappropriate fill volumes which may then be adjusted automatically or by a system operator. For this purpose, a check-weight scale is located in the filling station, which on a timed demand (at intervals determined by the customer), will rise up under an empty case to tare-weigh the case. If any of the fill volumes are out of control limits but within specifications because of a temperature change, a viscosity change or a change in specific gravity, the pump will automatically be re-calibrated by the PLC 23. A servo is used to register the correct number of counts corresponding to the correct fill volume. Any pump errors exceeding specifications are flagged and the operator is notified. When this in-process quality control system is in operation, the case remains stationary on the scale (the continuous-motion filling process is temporarily suspended).

The coordination between the servo-controlled walking-beam filling apparatus <b>107</b> and indexing assembly <b>9</b> essentially allows both cases (of four containers each) to be filled in the same amount of time as one stationary case of containers. This greatly improves the efficiency of the filling operation. Of course, the servo-controlled walking-beam filling apparatus <b>107</b> can easily be adapted for larger or smaller numbers and groupings of nozzles <b>72</b> to accommodate larger/smaller cases and greater or fewer containers.

After the filling operation is complete, the filled case is carried by the indexing assembly <b>9</b> onward to the capping area.

Once the case enters the capping area, case indexing assembly <b>9</b> transports the cases into the proper position under the continuous-motion capping apparatus <b>150</b>. Thus, the containers are maintained in proper alignment throughout the continuous-motion capping process. While the case indexing assembly <b>9</b> is capable of transporting cases singly, in this embodiment two cases are preferably transported in tandem to improve throughput.

Each of the two cappers in assembly <b>150</b> is a Capamatic™ multi-spindle continuous-motion capping machine, commercially available from NIC, preferably having two spindles/capping chucks. In this embodiment caps are fed out of a common central prefeeder assembly <b>11</b>. In exactly the same manner as the embodiment of FIG. 2, chutes deliver the caps to respective splitter plates each comprising a shallow guide plate with forked grooves for dividing caps between two transfer stations, and the capping chucks at each of the two cappers pick up the caps from the respective transfer stations. A like alignment mechanism <b>70</b> ensures that caps are correctly applied to containers by each spindle/capping chuck. This operation locates the containers <b>19</b> correctly for the tandem capping chucks and acts as a gripping mechanism to stabilize the containers <b>19</b> during capping. As before, the combination of pre-feeder assembly <b>11</b>, chute <b>16</b>, and rotary feed bowl <b>12</b> is commercially available from Farason Corp.

The capping chucks pick up caps from the splitter plates associated with tracks <b>100</b>A and <b>100</b>B. After grasping the caps, the capping chucks rise slightly such that the bottom edges of the caps just clear the splitter plates. The capping chucks then begin moving horizontally to follow the movement of the cases as the chucks descend to their respective containers. As before, the containers are locked into position by the jaws <b>71</b> of alignment mechanism <b>70</b>, thereby locating the containers correctly for the capping chucks and acting as a gripping mechanism for the containers as well.

The caps are put onto the containers sequentially, four-by-four, by the two pairs of capping chucks of each of the two Capamatic™ multi-spindle continuous-motion capping machines of capper assembly <b>150</b>. The leading pair of chucks tracks the forward row of containers in the leading case while the rearward pair of chucks simultaneously tracks trailing row of the second tandem case. After the caps have been put on the first two containers in both tandem cases, the tandem cases <b>17</b> are indexed to the forward position to cap the second set of two containers. Thus, the chucks also work in tandem applying caps to either the leading or trailing pair of containers in each case from one pair of cases to the next, and so on. After the capping operation is completed, the pair of cases is released to travel along conveyor <b>115</b> to the discharge area.

As before, as the caps are being put on the containers, inspections for missing and cocked caps are made using the existing servo torquing mechanism. A certain number of revolutions are required to install the cap correctly. If too few revolutions are performed, the cap is cocked. If too many revolutions are performed, then there is no cap in the chuck or the threads have been stripped.

After the containers are filled, capped and inspected, they proceed to the case sealer.

To coordinate and synchronize the operation of all active components, all of the following components are connected to the PLC: bar code reader <b>20</b>, flap opener <b>2</b>, optical inspection station <b>3</b>, case indexing assembly <b>9</b>, the servo-controlled walking-beam filling apparatus <b>107</b>, in-process quality control system, and continuous-motion capper assembly <b>150</b>. The interface with all components is again as shown in FIG. 3, thereby allowing the PLC to control the entire program flow.

FIGS. 22 through 27 collectively comprise a flow chart illustrating the sequence of operation of the embodiment of FIG. 21 as administered by the PLC to all connected components.

At step <b>220</b> the main power is turned on.

At step <b>222</b> the PLC resets all connected components.

At step <b>224</b>, the PLC performs a self-test on all connected modules. Should any faults be detected, the operator powers down the system at step <b>221</b> and the process returns to step <b>220</b>.

If all components pass the self-test, the PLC asks the operator if he wishes to change the existing system configuration (for a different container) at step <b>226</b>. If the user indicates yes, the PLC cycles through a series of changeover steps including an emergency stop at step <b>227</b>, menu selection of the new container settings and conformation thereof at step <b>228</b>, and a manual changeover of any necessary tooling parts at step <b>229</b>. Once the changeover is completed (or if the existing system configuration is not changed), then the PLC initiates a sequence of diagnostic steps shown at FIG. <b>23</b>.

At step <b>230</b> the PLC initiates the prefeeder assembly <b>11</b> and ensures that the rotary feed bowl <b>12</b> is filled. If the bowl is not filled per check at step <b>232</b>, step <b>231</b> is repeated as needed.

Once the bowl is full the prefeeder assembly <b>11</b> sorts and orients the caps (step <b>233</b>) and ensures that the chutes <b>16</b> (or lanes) are full and ready to go.

The process continues to step <b>240</b> where the axis conditions of the servo-controlled walking-beam filling apparatus <b>107</b> are checked, to step <b>242</b> where the variable frequency drive conditions are checked, to step <b>243</b> where the PLC conditions are checked. All critical operating parameters (heat sink temp, voltage, current, etc.) are continually monitored. Should any parameter fall outside the acceptable range, the PLC is notified.

A failure at any of the foregoing steps results in a full system stop at step <b>241</b>. If the conditions are acceptable the process continues to step <b>250</b>, where the operator is given the option of changing (manually overriding) any given system parameter. If the operator does call for a parameter change, the new parameter(s) are input to the PLC at step <b>251</b>, the input parameters are qualified. If acceptable, the new parameter(s) are transmitted to the relevant device(s) at step <b>252</b>, the transmission is verified in a known manner at step <b>253</b>. If the the new parameter(s) are not proper or are not properly sent, the operator is alerted at step <b>255</b>.

If the new parameter(s) are proper, the process moves to FIG. 24, which illustrates that present system can be run in 4 different modes, including Prime Mode for starting the filling pumps. If the system is not running in Prime Mode at step <b>310</b>, the PLC performs a series of checks for backup conditions at the main conveyor <b>115</b> (step <b>316</b>) and the case collection roller conveyor <b>5</b> (step <b>318</b>), and ensures that the filler tanks are okay (step <b>320</b>). If so, the filling apparatus <b>7</b> is enabled, the pumps are primed, and the main conveyor <b>115</b> and case indexing assembly <b>9</b> are started at step <b>321</b>. If the system is running in Prime Mode at step <b>312</b>, the PLC checks to see whether a line stop was initiated at step <b>262</b>. If so, the system implements an emergency stop, the operator may correct the fault at step <b>264</b>, and the systems completes a power down (returning to FIG. <b>22</b>). Assuming that a line stop was not initiated, (i.e., the line is running) mode selection is completed (the PLC polling for the current mode), the appropriate mode's functions will be completed. Automatic mode at step <b>322</b> is the normal fully automatic mode. Jog Mode at step <b>324</b> is a one-by-one mode individually initiated by the operator. Prime mode at step <b>326</b> (and as previously described) enables the filler at step <b>330</b>, starts the pumps at step <b>332</b> and then returns for operational mode selection. Index Mode at step <b>328</b> is a system calibration cycle.

If the system is set for automatic mode and there was no stop request during the previous cycle, the process continues to FIG. <b>25</b>. Here the flap opener <b>2</b> is enabled at step <b>261</b> and a check is run to ensure that the conveyor is full at step <b>262</b>. This check is governed by the PLC to ensure that an adequate backlog of cases is present to enable the flap opener <b>2</b> to run correctly.

Next, the cases proceed through the flap opener <b>2</b> at step <b>264</b> which automatically opens all four flaps of the case.

Next, the PLC <b>23</b> actuates and synchronizes the downstream case drive servos at step <b>265</b> as the cases approach optical inspection station <b>3</b>. If a case mis-feeds, the line is stopped at step <b>266</b> and the case may be manually repositioned

Next, the optical inspection process is initiated at step <b>267</b>. Here each open case is indexed into optical inspection station <b>3</b> where the vision system determines whether any containers are missing from the case, and whether any containers are not properly oriented. Cases that are improperly queued fail at optical inspection station <b>3</b> at step <b>268</b> and are rejected and are at step <b>269</b> urged off the system conveyor <b>15</b> by automatic pusher bar assembly <b>4</b>, and accumulated on case collection roller conveyor <b>5</b>. Defective cases also fail the optical inspection station <b>3</b> at step <b>270</b>, and these are also urged off the system conveyor <b>15</b> at step <b>271</b> as above.

If the case passes at the optical inspection station <b>3</b> (or if the vision system is disabled), the case is transferred down conveyor <b>115</b>, and both the case indexing assembly <b>9</b> and the servo-controlled walking-beam filling apparatus <b>107</b> are enabled at steps <b>280</b> and <b>281</b>, respectively.

At step <b>282</b>, two cases are picked up by indexing assembly <b>9</b>. If the cases are properly positioned, the PLC then initiates the filling process at step <b>283</b>, and the servo-controlled walking-beam filling apparatus <b>107</b> fills the containers as it tracks the continuous motion of indexing assembly <b>9</b>. It should be noted that two cases are not required. The system will fill only one if there happens to be only one on the lug chain at this time. Efficiency is gained with two. At step <b>284</b> the walking beam filling apparatus <b>107</b> checks to ensure that the containers are properly filled and reports a successful fill if appropriate to the PLC, the latter being responsible for determining whether or any particular case should be rejected or not. If yes, they are rejected at step <b>285</b>. Given a proper fill, the process continues to the capping stage as shown in FIG. <b>26</b>.

At step <b>290</b>, the PLC enables the first of the two Capamatic™ multi-spindle continuous-motion capping machines of capper assembly <b>150</b>, and the first case to be transferred is indexed into the capping station at step <b>291</b> by indexing assembly <b>9</b>.

In tandem with the foregoing steps, the PLC enables the second of the two Capamatic™ multi-spindle continuous-motion capping machines of capper assembly <b>150</b> at step <b>295</b>, and the second case to be transferred is indexed into the capping station at step <b>296</b> by indexing assembly <b>9</b>.

If the leading case is properly positioned at step <b>292</b>, the indexer <b>9</b> positions the case for capping at step <b>293</b>. The PLC then checks for coordination between the indexer <b>9</b> and the continuous-motion capping apparatus <b>150</b> at step <b>294</b>.

The same is concurrently done for the trailing case. If the trailing case is properly positioned at step <b>297</b>, the indexer <b>9</b> positions the case for capping at step <b>298</b>. The PLC then checks for coordination between the indexer <b>9</b> and the continuous-motion capping apparatus <b>150</b> at step <b>299</b>.

The tandem capping process is initiated at steps <b>300</b> and <b>302</b>. The forward capper in assembly <b>150</b> caps the leading row of containers in the case at step <b>300</b>. Upon completion, the caps are checked for errors at step <b>301</b>. Simultaneous with the capping of the containers in the first case, the rear capper in assembly <b>150</b> caps the leading row of containers in the trailing case at step <b>302</b>. Upon completion, the caps are checked for errors at step <b>304</b>. Rejects are subject to operator intervention at steps <b>303</b> and <b>305</b>, respectively. The conveyor is stopped, the operator is alerted, and the operator is responsible for deciding what to do with those particular cases. The forward and rear cappers in assembly <b>150</b> continue on to subsequent rows of containers in both cases, row by row, until the entire cases have been capped and checked for errors.

The process continues to FIG. 27, where the two fully capped cases are reject queued at step <b>306</b> and the system returns to Prime Mode at FIG. <b>24</b>. This reflects the fact that the system will complete all currently engaged functions before responding to a mode change. For instance, should the operator select Prime Mode while the machine is busy filling and capping cases already in process, the machine will complete those particular functions on those particular cases before attempting to initiate the Prime Mode sequence. The selected mode is monitored continually, and the system will will respond as soon as all engaged processes are allowed to complete normally.

Assuming a successful capping operation the cases are indexed out of the cappers of capping assembly <b>150</b> at step <b>307</b>, and indexer <b>9</b> initiates processing of the next pair of cases. Once the last case has been processed, the job ends.

The coordination of the servo-controlled walking-beam filling apparatus <b>107</b>, and the servo-controlled continuous-motion capping functionality of the capping apparatus <b>150</b> with the indexing of the cases by indexing assembly <b>9</b>, greatly improves the efficiency of both the filling and capping operations.

Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth in the appended claims.